Loopback Control Frame Routing for Cable Fault Tolerance

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Solution Overview

Problem

Factory automation systems experience control failures when communication cables disconnect, leading to equipment malfunction and reduced productivity.

Innovation Solution

Implementing a control system with a loopback communication device that allows control frames to be transmitted through a secondary communication route, ensuring continuous control even if the primary route is disconnected, and storing updated control frames from all slave devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single communication route is used for control data transmission, then the communication system is simple, but control stops when the communication cable breaks or disconnects

Engineering Contradiction:

Improvecontrol continuityVSAvoidcommunication system structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The communication route is segmented into multiple independent paths: a first communication route for normal operation and a second communication route for redundancy. This segmentation allows the system to switch between routes based on availability, ensuring control continuity while maintaining manageable complexity through modular route design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A second communication route is pre-configured as a backup before any disconnection occurs. The loopback communication device is positioned to intercept and redirect control frames through this alternative route when the primary route fails, providing beforehand cushioning against communication failures

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Productivity

If control stops when communication cable fails, then the communication system is simple, but productivity deteriorates due to equipment stoppage

Engineering Contradiction:

Improveequipment operation continuityVSAvoidcommunication stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The loopback communication device is pre-positioned in the communication path to automatically intercept and redirect control frames when disconnection is detected. This preliminary positioning enables immediate route switching without waiting for system-level error handling, maintaining productivity during communication failures

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The loopback communication device acts as an intermediary element between the controller and slave devices. It mediates control frame transmission by automatically switching between the first and second communication routes, ensuring continuous control flow and preventing equipment stoppage due to communication issues

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP3651420B1Control system and control method

Publication Date: 2023.10.04 OMRON CORP

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AI summary

This control system (1) is provided with a controller (11), a controller (12) which is a loopback communication device, a first communication route, and a second communication route. The controller (11) generates and transmits control frames to slave devices (21, 22, 23). The controller (12) performs loopback communication of the control frames. In the first communication route, multiple slave devices (21, 22, 23) are connected between the controller (11) and the controller (12) using communication cables (31, 32, 33, 34). In the second communication route, the first controller (11) and the second controller (12) are connected over a communication cable (35).